Heat exchanger tube with integral restricting and turbulating structure

ABSTRACT

A heat exchanger tube having an integral restricting and turbulating structure consisting of dimples formed by confronting indentations pressed into the sides of the heat exchanger tube. The dimples are comprised of indentations disposed in pairs which extend into the tube to such a depth as is necessary to significantly reduce the cross sectional area of the heat exchanger tube and provide a pair of converging, diverging flow nozzles to promote turbulence of the flue gases. The turbulence characteristics of the tube can be controlled by varying the size of the aperture of the nozzles. In certain applications, the dimples are located along the sides of the heat exchanger tube, thereby providing unobstructed drainage for liquids even when the tube is bent into a serpentine shape.

RELATED APPLICATION

[0001] This is a continuation-in-part application of U.S. Ser. No.09/205,955, filed on Dec. 4, 1998.

TECHNICAL FIELD

[0002] The invention relates to appliances which employ tubular elementsfor the purpose of conveying flue products and transferring heat tofluid media adjacent to the exterior of the tube. Product groupsinclude, but are not limited to, furnaces, water heaters, unit heatersand commercial ovens.

BACKGROUND

[0003] A typical method of making heat exchangers for a variety of gasand oil fired industrial or residential products is to bend a metal tubeinto a serpentine shape thereby providing multiple passes. Gases heatedby a burner at one end of the heat exchanger travel through the tubeinterior and exit the other end of the heat exchanger. While the hotflue gases are within the tube, heat is conducted through the metalwalls of the tube and transferred to the air or other fluid mediasurrounding the tube thereby raising its temperature. In order toachieve efficient heat transfer from the tubes, it is usually necessaryto alter the flow of gases by reducing their velocity and/or promotingturbulence, mixing and improved contact with the tube surface. A typicalmethod for achieving this is by placing a separate restrictiveturbulating baffle inside the tube. These baffles are typically metal orceramic. One problem associated with baffles in tubes is noise caused byexpansion or contraction of baffles or vibrations generated by themechanical coupling to components such as blowers or fans. Anotherdifficulty related to the use of baffles is that the heat exchanger tubecannot be bent with a baffle already inserted so that baffles must beinserted after bending, limiting the typical location of baffles tostraight sections of the heat exchanger tube which are accessible afterbending. In addition, the use of separate baffles increases the cost anddifficulty of assembling the heat exchanger.

[0004] A known alternative to baffles is the technique of selectivelydeforming the tube to change its cross section. Such deformation causesa restriction to the gas flow due to the change in cross section,achieving the effect of baffles. For example a known method is toflatten sections of the tube to achieve the desired restriction. Aproblem with the use of flattened sections is that this techniqueextends the cross section of the tube beyond that of the tube withoutdeformations, creating low spots in horizontal sections. Additionally,the flattened sections prevent the tube from passing through a hole ofapproximately the tube outside diameter as required for assembly in someapplications.

[0005] While deformation of the heat exchanger tube can replace the useof baffles in some applications, the deformation technique has had lessthan satisfactory results when applied in commercial and lightcommercial heating and air conditioning units. The design of mostheating and air conditioning units is such that the heat exchanger islocated downstream of the evaporator section for cooling. Therefore,during use for air conditioning the cool air passing over the heatexchanger lowers the tube temperature below the dew point of air insidethe tube, resulting in condensation inside the tube. Currentconfigurations of tube deformation experience problems in draining thiscondensation from the tube due to low spots in the horizontal sectionsof the tube. The low spots, which are caused by restricting deformationsprevent the flow of liquid, allowing condensate to puddle and increasethe likelihood of corroding the tube. For this reason baffles are oftenused in heating and air conditioning unit heat exchangers to avoidpremature failure due to corrosion.

SUMMARY OF THE INVENTION

[0006] An object of the present invention is to provide a single pieceheat exchanger tube which incorporates an integral restricting andturbulating structure and is suitable for use in residential heating,commercial heating/air conditioning and cooking units.

[0007] A more particular object of the present invention is to provide aheat exchanger tube with an integral restricting and turbulatingstructure which allows for drainage of liquid from the tube even whenlocated in a horizontal section of the tube. Another more particularobject of the invention is to provide a heat exchanger tube which canhave integral restricting and turbulating structures between bends in aserpentine shaped heat exchanger.

[0008] The heat exchanger tube of the present invention generallycomprises a metal tube having open ends. At one end is an inshot gasburner which heats gases flowing into the tube. Hot gases which haveflowed through the length of the tube are exhausted out the other end ofthe tube. In many applications, the tube is bent into a serpentine shapeto form several passes.

[0009] In order to maximize the efficient transfer of heat from the hotgases within the tube to the air or other fluid media outside the tube,a restricting and turbulating structure is used to slow the rate oftravel of the hot gases through the tube. The restricting andturbulating structure of the present invention comprises dimples formedin the sides of the heat exchanger tube. The heat exchanger tube withdimples pressed in it maintains a cross sectional profile that does notextend beyond that of the undimpled tube, preventing difficultiesassociated with flattening techniques. The dimples are comprised ofpairs of indentations opposite one another along the tube. Theindentations may extend into the tube to such depth as is necessary toprovide the required restriction. These indentations are locateddirectly opposite from each other, constituting a dimple whichsignificantly reduces the cross sectional area of the tube. This dimpleform provides a structure approximating a pair of converging, divergingnozzles. This two nozzle dimple structure provides improved turbulence.In applications requiring condensate drainage, the dimples arepreferably located only along the sides of the tube, with the axis ofthe dimple being perpendicular to the vertical centerline of the tube asit is oriented in use. This provides a non-deformed tube along thebottom of the horizontal sections, which provides liquid condensate andan unobstructed flow path. In short, the dimples do not obstruct theflow of liquid out of the tube. Exact dimple geometry and location maybe adjusted to maximize efficient turbulence of the hot gases, dependingon the final shape and orientation of the tube.

[0010] The present invention provides a heat exchanger tube suitable foruse in commercial and light commercial heating and air conditioningunits as well as other commercial and residential products. The presentinvention incorporates an effective restricting and turbulatingstructure which does not require additional parts such as baffles. Thepresent invention provides a heat exchanger tube having a cross sectionwhich does not extend outside the cross section of the heat exchangertube without dimples. In addition, the present invention does notinterfere with drainage of condensation, even when the heat exchangertube is bent into a serpentine shape, thereby reducing the possibilityof corrosion. In applications where condensate drainage is not an issue,dimples can be located rotationally at any desired angle from each otherto provide additional mixing and turbulence. The present invention alsoprovides a superior turbulating method by providing adjacent converging,diverging nozzles in a tubular heat exchanger regardless of shape ortube orientation. The turbulating characteristics of the presentinvention can be controlled by controlling an aperture size of thenozzles.

[0011] Other objects and advantages and a fuller understanding of theinvention will be had from the following detailed description of thepreferred embodiments and the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

[0012]FIG. 1 is a side plan view of a portion of a heat exchanger tubemade in accordance with the present invention;

[0013]FIG. 2 is a top plan view of the heat exchanger tube as seen fromthe plane indicated by the line 2-2 in FIG. 1;

[0014]FIG. 3A is a section view taken along line 3-3 of FIG. 2 of anembodiment of the present invention;

[0015]FIG. 3B is a section view taken along line 3-3 of FIG. 2 of anembodiment of the present invention;

[0016]FIG. 4 is a section view taken along line 4-4 of FIG. 3;

[0017]FIG. 5 is a perspective view of a heating and air conditioningunit having heat exchanger tubes made in accordance with the presentinvention;

[0018]FIG. 6 is a side plan view of the heat exchanger tubes of FIG. 5;

[0019]FIG. 7 is cut away view of a residential/light commercial waterheater having a flue tube made in accordance with the present invention,instead of a baffle as used in current practice;

[0020]FIG. 8 is a front plan view of a plurality of heat exchanger tubesmade in accordance with the present invention; and,

[0021]FIG. 9 is a side plan view of the heat exchanger tubes of FIG. 8.

DESCRIPTION OF PREFERRED EMBODIMENT

[0022] FIGS. 1-9 illustrate the construction of heat exchanger tubes 10,30, 10′ constructed in accordance with preferred embodiments of theinvention. The heat exchanger tube of the present invention may be usedin many heating applications including, but not limited to, furnaces,water heaters, unit heaters and commercial ovens.

[0023] To facilitate the explanation, the tube construction shown inFIGS. 1-4 will be described first in connection with its use as a fluetube in a water heater (shown in FIG. 7). Referring also to FIG. 7, agas heated residential water heater 21 is shown having a flue tube 10 ofthe present invention extending upwardly through a water heating chamber22. The flue tube 10 consists primarily of a metal tube 12. The metaltube 12 has an interior surface 16, an inlet end 17, and an outlet end19. At least one parabolic shaped indentation 15 is pressed into themetal tube 12. In the preferred embodiment, the indentations 15 arepressed into the metal tube 12 in pairs located across the tube 12 fromone another to the depth necessary to provide the desired restriction,up to the point of contacting the opposite indentation, see FIG. 2.Confronting/opposing indentations 15, together define a dimple 20. Thenumber of dimples 20 used as well as the exact shape of the dimples maybe adjusted to vary the restricting and turbulating characteristics ofthe flue tube 10. As seen in FIG. 7, a gas burner 18 is disposed at thetube inlet end 17 which heats gases that move through the tube 10 andare exhausted through the outlet end 19 and into the water heater ventsystem 25. The heat from these gases is conducted through the walls ofthe metal tube 10 to heat the water in the water heating chamber 22. Theillustrated dimple structure when used in a water heater application, ismore resistant to deformation and/or collapse of the tube 10 due tohydrostatic forces exerted by the water in the heating chamber 22, ascompared to prior art tube forming or flattening methods.

[0024] FIGS. 1-4 show the heat exchanger tube 10 in detail. FIG. 1 showsthe indentations 15 which preferably have a parabolic shape and aredisposed in opposing or confronting pairs to constitute the dimple 20,positioned along the length of the metal tube 12 so as to significantlyreduce the cross sectional area of the tube. Each indentation 15 maycontact the indentation 15 opposite it to form an interior cross sectionshown in FIG. 3A, or it may confront the opposing indentation withoutcontact resulting in significant reduction of the cross sectional areaas in FIG. 3B.

[0025] A maximum spacing of the confronting indentations 15 of about 12%of the tube diameter is appropriate for practice of the invention. Inthis manner, the indentations form a pair of adjacent,converging/diverging nozzles in the tube to enhance the heat transfer bydisrupting the fluid boundary layer at the inner tube surface. Theexpanding fluid streams exiting the nozzle interact to produceturbulence downstream even at low Reynolds flow numbers (low flowvelocities). An aperture 31 of each of the adjoining nozzles iscontrolled by the depth of the confronting indentations 15. Controllingthe aperture opening of the nozzles allows precise control of pressuredrop through the tube and the flow characteristics as necessary toconform to the design of the tube (i.e. the number of serpentine passesand length of each pass) and the product to which the tube will beapplied.

[0026] When the indentations do not contact one another as in FIG. 3B,the space between the indentations 15 remains a “dead flow area” withina range of spacing between 0-12% of tube diameter, allowing control ofthe flow and pressure drop characteristics of the nozzle by controllingthe size of the apertures 31. The size of the apertures 31 can beselected by varying the depth of the indentations 15, allowing the useof a single tool form design for each tube diameter and aperture size.This permits optimization of the tube(s) 10 for heat transfer andefficiency in the exchanger design with respect to cabinet configurationand external circulating airflow.

[0027] In some applications (and as will be described in connection withFIGS. 5 and 6), the dimples 20 are located only along the sides of themetal tube 12 (see FIG. 3A) so that the bottom interior surface 13 isfree from obstruction by dimples to allow drainage of fluid from theheat exchanger tube 10 even when the heat exchanger tube is bent into aserpentine shape as shown in FIG. 5. By locating the dimples on a 0-45°axis relative to the vertical axis as shown in FIG. 3B (a 45° angle isdepicted in FIG. 3B), the top, bottom, and side interior surfaces 14,13, and 36 respectively of the tube 10 may be made free from theobstruction by dimples to allow for drainage of fluid when the tube isbent along the vertical or horizontal axis. The heat exchanger tube 10maintains a circular cross sectional profile after dimples 20 have beeninstalled as can be seen in FIGS. 3A, 3B, and 4. FIG. 1 shows a sideplan view of the heat exchanger tube 10 with a dimple 20. At the centerof each indentation 15 is an area 11 which is the area over which theindentation 15 may contact the indentation opposite it. FIGS. 3A and 3Bshow an interior view of the dimple 20 having nozzle-like structures.

[0028]FIG. 5 shows a plurality of serpentine shaped heat exchanger tubes30 used in a heating and air conditioning unit 40. The heat exchangertube 30 has six passes. Although dimples 20 are shown only in two passesof the metal tube 12, they may be located anywhere along the length ofthe metal tube at the designer's discretion. An inshot burner 32 isdisposed at each heat exchanger tube inlet end 34.

[0029] When the heating and air conditioning unit 40 is used as afurnace, the burners 32 heat gases which pass through the six passes ofthe serpentine shaped heat exchanger tube 30. A fan 41 blows air acrossthe heat exchanger tube 30 to be heated. Hot air then moves from theheating and air conditioning unit 40 via a duct 45. When the heating andair conditioning unit 40 is used as an air conditioner, the burners 32are not lit. Refrigerant is vaporized in the evaporator 43, causing thecoils 49 of the evaporator 43 to become cold. The fan 41 draws airacross the evaporator coils 49 where it is cooled and moves across theheat exchanger tube 30 prior to moving out of the heating and airconditioning unit 40. The refrigerant is then moved to the condenser 42where it returns to liquid form. When the cold air moves across heatexchanger tube 30, the temperature of the air within the heat exchangertube 30 cools to below the dew point, forming condensation within theheat exchanger tube 30. In most cases, the horizontal passes of the tubeare parallel. Condensation does drain and does not pool in any portionof the tube. In the example shown, condensation drains more positivelyout of the heat exchanger tube 30 due to the constant downward slope ofthe horizontal portions of the tube. Since the dimples 20 are locatedonly along the sides of the heat exchanger tube 30, the flow ofcondensation is unobstructed and hence no pooling of condensation occurswithin the heat exchanger tube 30.

[0030] Referring to FIGS. 8 and 9, a heat exchanger tube set 50 for usein a vertical gravity type gas wall furnace is shown having a pluralityof heat exchanger tubes 10′ of the present invention. The inlet ends 17′are connected to a header plate 51 with gas burners 52 connected on theother side of the header plate to provide heat to the gases within theheat exchanger tube 10′. The outlet ends of the heat exchanger tubes areconnected to an outlet bracket 53 where the heated gases are exhausted.See the explanation for FIGS. 1-4 above for the specific operation ofthe heat exchanger tubes 10′ in this embodiment. As with the otherdisclosed embodiments, the dimples 20 may be disposed at any locationalong the length of the metal tube 12′ as per design requirements.

[0031] The preferred embodiments of the invention have been illustratedand described in detail. However, the present invention is not to beconsidered limited to the precise construction disclosed. Variousadaptations, modifications and uses of the invention may occur to thoseskilled in the art to which the invention relates and the intention isto cover hereby all such adaptations, modifications, and uses which fallwithin the spirit or scope of the appended claims.

We claim:
 1. A heat exchanger apparatus comprising at least one singlepiece tubular member having a generally circular cross section, saidtubular member further comprising a restricting and turbulatingstructure, said structure comprising at least one opposing pair ofobstructions having a generally parabolic dimple shape disposed withinsaid tubular member and wherein the entire obstruction of each pair ofobstructions are aligned with respect to each other and project intosaid tubular member until they confront one another to form a pair ofadjacent converging, diverging nozzles each having an aperture throughwhich a fluid may flow and maintain the normal radius tube shape withinthe circular cross section along the entire tubular member.
 2. The heatexchanger apparatus of claim 1 wherein said obstructions project intosaid tubular member until they contact one another.
 3. The heatexchanger apparatus of claim 1 wherein said obstructions are spacedapart from one another by a predetermined distance.
 4. The heatexchanger apparatus of claim 1 wherein said predetermined distance isbetween 0-12% of a diameter of the tubular member.
 5. The heat exchangerapparatus of claim 1 wherein said opposing pairs of obstructions arelocated along the sides of said tubular member such that when saidtubular member is viewed from one end, said pairs of opposingobstructions are disposed at an angle relative to the vertical axis ofsaid tubular member.
 6. The heat exchanger apparatus of claim 5 whereinsaid obstructions are located at a 45° angle relative to said verticalaxis of said tubular member.
 7. The heat exchanger apparatus of claim 5wherein said obstructions are located on an axis oriented at an angle ofbetween 0 and 45° relative to said vertical axis.
 8. A heat exchangerapparatus comprising an inshot burner and at least one single piecetubular member having a generally circular cross section, said tubularmember further comprising a restricting and turbulating structureintegral to said tubular member and disposed within said tubular member,said restricting and turbulating structure comprising at least one pairof opposing indentations having a generally parabolic dimple shapeextending into said tubular member until said indentations confront oneanother, the entirety of said opposing indentations of a pair beingaligned with respect to each other, said pairs of opposing indentationsdisposed within said tubular member to form a pair of adjacentconverging, diverging nozzles.
 9. The heat exchanger apparatus of claim8 wherein said obstructions project into said tubular member until theycontact one another.
 10. The heat exchanger apparatus of claim 8 whereinsaid obstructions are spaced apart from one another by a predetermineddistance.
 11. The heat exchanger apparatus of claim 8 wherein saidpredetermined distance is less than 13% of a diameter of the tubularmember.
 12. The heat exchanger apparatus of claim 8 wherein saidopposing dimples are disposed within said tubular member at an anglewith respect to a vertical axis of said tubular member.
 13. The heatexchanger apparatus of claim 12 wherein said obstructions are located ata 45° angle relative to said vertical axis of said tubular member. 14.The heat exchanger apparatus of claim 12 wherein said obstructions arelocated on an axis oriented at an angle of between zero and forty-fivedegree relative to said vertical axis.
 15. The heat exchanger apparatusof claim 8 wherein said tubular member is bent into a serpentine shape.16. The heat exchanger apparatus of claim 8 comprising a plurality ofsaid tubular members.